ACME spearheads eco-friendly transition in district heating across the EU

ACME, Canada, is spearheading the Eurpean Union’s transition from fossil fuel systems to advanced, high-efficiency electrode boilers. This transition not only promises a significant reduction in carbon emissions but also enhances the energy efficiency of district heating networks across the EU.

District heating, crucial for centralized heat generation and distribution in urban areas, is undergoing a transformation with the installation of cutting-edge electrode boilers. These boilers are praised for their ability to operate on electricity derived from renewable sources such as solar, wind, and hydro power, marking a significant step towards sustainable energy use.

Robert Presser, vice president of Acme Engineering, explains the technological superiority of electrode boilers, “Unlike traditional gas or oil-fired boilers, electrode boilers can achieve full capacity in about 90 seconds with a 100% turndown ratio, ensuring that no energy is wasted. This rapid responsiveness, coupled with the absence of combustion, makes these boilers highly efficient and environmentally friendly.”

The electrode boilers utilized in these upgrades, such as Acme’s CEJS and CEJW models, are capable of converting nearly 100% of electrical energy into heat, eliminating losses typically associated with stack or heat transfer. With capacities ranging from 6MW to 68MW, these boilers are designed to meet the rigorous demands of large-scale heating needs while occupying minimal space.

Presser also highlights the economic and operational benefits of these boilers, “Electrode boilers are not only cleaner but also more compact and easier to install compared to conventional systems. They require fewer components and minimal maintenance, reducing long-term costs and enhancing reliability.”

EU municipalities and businesses are increasingly recognizing the value of integrating these advanced technologies into their district heating frameworks. As the effects of climate change intensify, the shift towards these efficient, renewable-energy-powered systems is seen as critical in meeting both current and future energy needs while adhering to stringent decarbonization targets.

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One Minute Mentor: vacuum furnace setup

A simple but most effective and very flexible vacuum furnace setup, the single-chamber furnace, consists of one chamber in which the workpiece is both heated (convectively, through vacuum heating) and cooled. Cooling or quenching is accomplished by a closed-loop cooling system.

The pressure vessel is filled with inert gas. This gas is circulated inside the chamber, blowing the inert gas across the workpieces to pick up heat and for further recooling across an internal or external heat exchanger. In order to quench rapidly enough to obtain the desired microstructure of tool steels in various sizes and shapes, it is necessary to increase the pressure and/or flow patterns of the quench gas (usually nitrogen). This is accomplished by high-velocity, high-pressure blowers that have reported cooling gas pressures of up to 20 bar. Turbine powers up to 450 kW are necessary to handle these quenching processes.

For more information, click on the link below (subscription required). Then scroll to Figure 15. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014  https://doi.org/10.31399/asm.hb.v04d.a0005958

Solar Manufacturing ships Mentor Pro Furnace to a global leader of wire mesh products

Solar Manufacturing, Sellersville, PA, has shipped a Mentor Pro Model HFL-3036-2IQ vacuum furnace to a customer specializing in engineered knitted wire mesh solutions. 

They are a USA-based company and a global supplier for the automotive, food service, and janitorial industries. The furnace will be primarily utilized for vacuum annealing materials that are susceptible to adverse effects of their mechanical properties when exposed to any levels of oxygen or nitrogen.

The Mentor® Pro features a molybdenum shielded hot zone measuring 18” wide x 18” high x 36” deep, capable of operating temperatures up to 2400°F, and a workload weight capacity of up to 1,000 lbs and includes the SolarVac® Essentials PLC-based control system. The internal gas cooling system with a 50 HP drive motor is capable of quenching workloads at 2-bar positive pressure in either nitrogen or argon.

Jason Davidson, regional sales manager, said that, “Our customer started running trials with our affiliate commercial heat treater, Solar Atmospheres. Once the trial results proved the heat-treat cycle, and the furnace demonstrated it could process the required quantities, the customer had confidence to place the purchase order with us.”

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Can-Eng commissions mesh belt furnace overseas

Can-Eng Furnaces, Niagara, Ontario,  has commissioned a continuous mesh belt heat-treat system for the production of high-quality automotive fasteners in Italy.

This project in the Piedmont region of Italy was one of four installation locations for this globally recognized producer of specialty automotive fasteners that span from Europe, South America, Mexico, and the United States of America.

Can-Eng Furnaces International Ltd was chosen to supply its state-of-the-art systems based on proven reliability, efficiency, and soft-part-handling features — hallmarks of Can-Eng’s mesh belt furnace systems. The new, high-volume fastener system features energy efficient combustion and waste heat recovery systems, atmosphere-controlled mesh belt hardening system, oil quench, post wash system, temper furnace, soluble oil system, bi-directional conveyor discharge, and Can-Eng’s Level 2 SCADA system. Can-Eng’s PET™ system provides the user with access to vital Industry 4.0 data which includes product traceability, detailed process data for continuous process improvements, comprehensive equipment diagnostics, cost analysis, and inventory management.

https://thermalprocessing.com/news/can-eng-commissions-mesh-belt-furnace-overseas/

Solar Atmospheres awarded Lockheed Martin space systems approval

Solar Atmospheres, Greenville, SC, has announced that it has been awarded Lockheed Martin Space Systems approval. With this approval, now all five Solar Atmospheres facilities are an option for our customers with Lockheed Martin requirements for thermal processing services.

Steve Prout, President of Solar Atmospheres’ Greenville facility states: “We are proud to once again provide our customers in the Southeastern U.S. with another regional option for aerospace and defense thermal processes, saving them time and money while continuing to deliver the high level of quality required.”

With the ability to support vacuum thermal processing needs ranging from development cycles to 50,000 pound loads at temperatures of up to 2400°F, Solar Atmospheres provides AS9100 and Nadcap quality accredited heat treatments, providing our customers with the confidence their product is being processed as specified.

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One Minute Mentor: Vacuum Furnaces

Driven by the development of new tool steels—which were property-wise tailor made for applications such as aluminum die casting, drilling, and tools and dies for the plastic industry—but also due to rising dimensions of the tools, the demands on vacuum-hardening technology have changed in recent decades. One of the most important considerations that must be met is the accomplishment of highest dimensional stability with optimal microstructural properties and minimal change of the surface of the workpieces. Minimizing exposure to air during the heat treatment by reducing the quantity of oxygen in a heat treatment furnace, as with creating a vacuum, is an excellent method for preventing changes in surface appearance and chemical composition.

For more information, click on the link below (subscription required). Then scroll to Figure 14. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014  https://doi.org/10.31399/asm.hb.v04d.a0005958

Process and parameters for laser assisted localized heat treatment in manufacturing applications

University of Azurem, Portugal, presents information and results relevant for the development of a laser heat treatment process suitable to improve manufacturing in high strength steel and high strength aluminum alloys.

The challenges with manufacturing of such materials include springback effect and localized fracture. The study details heat cycle and their effect in metallurgical state and mechanical properties. Such laser induced heat treatment process is intended to improve the forming behavior of metal parts in challenging metal forming conditions, in particular for the delay or avoidance of localized fracture. Results for strength, hardness and elongation properties are presented. It was concluded that it is possible to locally modify yield strength and hardness using process duration suitable for industrial applications. Suitable process temperature ranges and target heat cycles were identified. 

A positive effect of material softening was observed in both hardness and strength properties. However, in some cases a reduction of ductility is apparent which must be considered for targeted industrial applications. The dimension of the heat-affected zone was also considered as design variable for the industrial process development. Preliminary results were obtained in a development forming tool.

https://journals.sagepub.com/doi/full/10.1177/09544054221135684

Ipsen Launches “Ipsen Connect,” to Streamline Customers’ Operations

Ipsen, Cherry Valley, IL, announced a new digital gateway, Ipsen Connect. The customer service portal simplifies access to essential resources, including order history, service requests, and furnace documentation.

Key features of Ipsen Connect include:

  • Convenient part management: Request or reorder parts, view order history, and access furnace documentation seamlessly.
  • Streamlined service requests: Schedule maintenance, troubleshooting, or calibration appointments in just a few clicks.
  • Best practices and expert insights: Access troubleshooting guides, online training videos, and answers to frequently asked questions.
  • Real-time updates: Keep your operations informed and on track with live updates, including order status, active quotes, planned maintenance, and scheduled service appointments.

https://ipsenglobal.com/knowledge-center/ipsen-launches-a-cutting-edge-digital-platform-ipsen-connect-to-streamline-customers-operations/

Constellium Ravenswood to receive $75 million for zero carbon technology

Constellium, Ravenswood, WV, announced that it has been selected by the U.S. Department of Energy (DOE) Office of Clean Energy Demonstrations to begin award negotiations for up to $75 million in Bipartisan Infrastructure Law and Inflation Reduction Act funding as part of the Industrial Demonstrations Program (IDP). This investment will help fund the implementation of breakthrough low-to-no emissions technologies in Constellium’s Ravenswood facility, supporting the decarbonization of the casthouses, the plant’s most energy intensive operation.
This investment will support the installation of low-emissions SmartMelt furnaces that can operate using a range of fuels, including clean hydrogen, paving the way towards a zero carbon casthouse. In addition to reducing carbon emissions, the project is expected to help maximize recycled scrap intake, and to improve worker safety with the introduction of a hands-free casting process.
The project will also contribute to the local communities around Ravenswood with a dedicated budget to build a new training and wellness center for all employees and an onsite childcare, and to provide financial and technical resources for local schools and universities.
Constellium Ravenswood will now enter negotiations on the specific terms of the investment, including operational milestones, and timing of access to funds throughout the life of the project, estimated to be approximately five years. The final details of the project investment are subject to these negotiations.

https://www.constellium.com/news/constellium-ravenswood-selected-by-us-doe-to-receive-usd75million-investment

Sudosilo S.A. commissions new Nitrex installation

Nitrex, Quebec, is helping Sudosilo S.A., a leading commercial heat treatment service provider in South America, bring premier nitriding to the Argentine industrial sector with the recent commissioning of a turnkey installation. This newly operational nitriding system, represents a significant milestone as the first of its kind in Argentina, offering third-party heat treatment services to the region.

At the forefront of technological advancement, Sudosilo has embraced cutting-edge technologies to cater to various sectors, including aluminum injection, aluminum extrusion, forging, and oil applications. The integration of a NITREX system into its operations is set to establish a new benchmark for quality and precision in nitriding treatments.

The new Nitrex system adheres to CQI-9 guidelines for automotive heat treatment processes and NADCAP requirements for aerospace applications. This aligns Sudosilo with international standards, positioning the company to meet the exacting demands of both Argentine and South American markets for quality, innovation, and unparalleled service. 

The successful commissioning of the turnkey system, featuring a pit-type furnace model NX-1015 with Nitreg® controlled nitriding, Nitreg®-C controlled nitrocarburizing, and ONC® post-oxidation process technologies, was completed in November 2023. These advanced technologies ensure a uniform case depth and precise management of nitriding/nitrocarburizing/oxidation layer formation, optimizing the mechanical properties of tooling and dies. Nitreg® and Nitreg®-C contribute to enhancing surface hardness and fatigue resistance, while ONC® improves corrosion resistance. Notably, the system eliminates the need for post-finishing operations and boasts a substantial load capacity of 4400 lbs. (2000 kg). Marathon Systems Control, serving as a Nitrex representative for Latin America, played a pivotal role in expertly executing the system installation and finalizing the process validation.

https://www.nitrex.com/